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Taylor Flow Continuous Reactor | High Purity and Uniform Chemical Reaction
Our LCTR Taylor Flow Chemical Reactors are designed and manufactured in South Korea by Laminar. Laminar has been receiving global acclaim for its successful implementation of Taylor-Couette flow into chemical reactors for it’s application to industries requiring high purity chemical production or reaction of nano sized particles.
These Taylor Flow Chemical Reactors produce the combined benefits of traditional tank-type reactors and Plug flow reactors by offering high purity outputs, repeatability, suitability for production of nano particles, while maintaining user friendliness and ability to control the synthesis process.
Most notable applications of the Taylor Flow Chemical Reactors are secondary batteries, graphene oxide productions, synthesis of food additives, pharmaceuticals and nanomaterials.
Composition of Taylor Flow Continuous Reactor
Taylor Fluid Flow Reactor uses two cylinders to have the reacted fluid fed into the space between the inner and outer cylinder. While the inner cylinder is rotated by the motor, the solution moves in the direction of rotation in a stream. Laminar Taylor Flow Reactor is a first reactor to apply Geoffrey Ingram Taylor’s Taylor fluid flow to the reaction mechanism, where a turbulent flow is generated by transferring rotational speed of the inner cylinder to stabilize the fluid. Laminar Continuous Taylor Flow (LCTR) can synthesize new materials by reacting liquid to liquid, gas to liquid, and solid to liquid under the presence of solvent.
When Laminar’s Continuous Taylor Flow reactor is applied in the production of lithium-ion battery’s cathode material, the reaction cycle time is 8 times faster than a batch type reaction tank because of its continuous, uniform cycle, micro-mixing capability as opposed to batch reactor’s macro-mixing limitation, and a much stronger mixing intensity and mass transfer velocity.
- Reactant Feeding Port (Multiple ports can feed reactants in gas, liquid or solid phase)
- Temperature Control Outlet
- Temperature Control Inlet
- Drain
- Reaction Product Outlet (Slurry)
- Agitation Bar, Rotational Shaft
- Reaction Area
- Reaction Solution
Advantages of Taylor Flow Continuous Reactor
1. Continuous High Yield Production
Taylor Vortex Flow Chemical Reactors allow constant input flow of reactants from several ports into the double cylinder system, and provides 95% or more yield. Common feedback from our reactor users is that using the Taylor Flow Chemical Reactor helps them maximize utilization rate of the reactants and have close to zero loss of materials. In a zirconia bead emulsion polymerization process that used Taylor Flow Reactor, vibration mill and homogenizer separately to compare the result shows that the Taylor Flow Chemical Reactor provided the highest yield, and spherical rate while producing smallest, densest and equally sized uniform particles.
Input (A+B+C) = Output (D)
2. Combined Benefits of Batch Reactor and PFR Reactor
Taylor Flow Continuous Chemical Reactor provides both advantages of conventional Tank reactors and the tubular Plug Flow Reactor (PFR) minus the limitations of either conventional reactors. Laminar’s Taylor Flow Chemical Reactors produce remarkably high purity end materials, with repeatable processes, and are suitable for production of nano-sized materials. While keeping high quality and uniformity of particle sizes, it can also be used for large production in a continuous production, and be operated easily with minimal training. It is a continuous chemical reaction system that provides consistently pure and uniform outputs.
Tank Reactor
- Easy operation
- Mixer function
- Synthesis process can be monitored and controlled
- Suitable for large production
Tubular Plug Flow Reactor
- High purity product produced
- High repeatability
- Suitable for production of nano materials
3. High Purity Material
Taylor Vortex Flow Chemical Reactor produces reacted products at a higher purity and yield than any other conventional reactors in the market. In comparison to a batch type reactor that often needs several batches to get increasing purity, Taylor Flow Reactors can achieve 98.2% purity on the 1st try. Production of high purity products enhances production efficiency, and reduces manufacturing cost and loss of reaction significantly.
Fluid Dynamics of Conventional Reactor
Fluid Dynamics of a Taylor Flow Reactor
No Dead Zones
4. Exothermic Reaction Control Feature
Taylor Flow Chemical Reactor provides strict operation temperature control to maintain steady reaction and prevent and unsafe exothermic reaction.
5. High Uniformity in Product Particles
Taylor Flow Chemical Reactor produces dense product grain particles consistently that are uniform in shape and size. It’s ability to produce uniform particles is because the homogeneous micro-mixing environment inside the reactor cylinders push the reaction particles to react at the same time with minimal fluctuation in it’s reaction time.
Microscopic View of Product Particles
CSTR – Continuous Stirred Tank Reactor
LCTR – Continuous Taylor Flow Reactor
6. Reduced Cycle Time & Enhanced Production Efficiency
Taylor Flow Chemical Reactor provides strong agitation power that enhances reactor productivity. In the same given cycle time as a comparable batch reactor, Taylor Flow Chemical Reactor can produce 20 times more output which makes them excellent substitute or addition for mass production reaction facilities.
Laminar’s Taylor Flow Chemical Reactor’s mixing power is 7 times stronger and it’s mass transfer speed is 4 times faster than batch type reactors in a same reaction. A 5L volume reactor using Taylor flow can produce equivalent output as a 20L volume CSTR equipment in the same given time.
Taylor Vortex Flow Chemical Reactor Specifications | LCTR Models
Taylor Vortex Flow Chemical Reactors come in 5 different models that can be customized further to meet the requirements of applicable use. A summary of all LCTR models can be found here:
LCTR Mini-V
Working Volume: 20ml
Maximum Agitation Speed: 1500rpm up to 5000rpm with customization
Permissible Operation Temperature: Generally up to 90°C but up to 600°C with customization
Material: SUS316, Teflon Coating, Hastelloy-C, Inconel, etc
Dimension (L/W/H): 274mm x 525mm x 617mm
Weight: 40kg
Suitable for: Pharmaceutical research, Quantum dot, High value materials research and development, Laboratory use
LCTR LAB II (LAB II V and LAB II H)
Working Volume: 100ml – 200ml
Maximum Agitation Speed: 1500rpm up to 5000rpm with customization
Permissible Operation Temperature: Generally up to 90°C but up to 600°C with customization
Material: SUS316, Teflon Coating, Hastelloy-C, Inconel, etc
Dimension (L/W/H): LAB II-V 500mm x 500mm x 1178mm | LB II-H 1102mm x 450mm x 574mm
Weight: 85kg – 120kg
Suitable for: Universally used for Research & Development Projects for new processes, or new products, and Optimization of existing manufacturing process
LCTR TERA
Working Volume: 1L
Maximum Agitation Speed: 1500rpm up to 3000rpm with customization
Permissible Operation Temperature: Generally up to 90°C but up to 600°C with customization
Material: SUS316, Teflon Coating, Hastelloy-C, Inconel, etc
Dimension (L/W/H): 1470mm x 700mm x 1150-1157mm
Weight: 450kg – 650kg
Suitable for: Secondary battery development projects, smallest model with PH control function for chemical reactions with critical PH requirements
LCTR PETA
Working Volume: 5L / 10L / 50L
Maximum Agitation Speed: 1200rpm to 1500rpm depending on the working volume
Permissible Operation Temperature: Up to 90°C
Material: SUS316, Teflon Coating, Hastelloy-C, Inconel, etc
Dimension (L/W/H): 1760mm x 500mm x 851mm / 2330mm x 700mm x 1200mm / 3400mm x 1300mm x 1600mm
Weight: 600kg / 1200kg / 3000kg
Suitable for: Pilot scale production, Small quantity batch productions, large variety production requirements
Taylor Flow Chemical Reactor Applicable Projects
Pharmaceutical
- Drug Production
- Protein Synthesis
- Enzyme Synthesis
- Sulfamerazine Crystallization
- Enantiomer Separation
Food Additives
- Protein Additives
- Amino Acid Production
- Functional Food Materials
Petrochemical Industry
- Dimethyl Terephthalate Melt Crystallization (Isometric Separation with 95% Purity)
Fine Chemical Industry
- Dye Manufacturing
- Surfactant Production – Detergents, Emulsifiers
Battery
- NCM, NCA
- LLZO (For Lithium Batteries)
- (MnCo)(OH)2
Electronics and Semiconductor Industry
- Secondary Battery
- Semiconductor
- Display Units and Components
- Zirconia Bead Emulsion Polymerization
- Quantum Dot Core Shell Processing
- Metal Nano Particle Capping
- OLED Light Emitting Material Recrystallization
High Value Chemical Recovery
- For Recovery and Recycling of High Priced Materials
- Water Treatment (by product)
- Graphene Oxide Exfoliation
- Graphene Exfoliation
- Carbon Nano Composite Reduction
- Graphene/CU Nano-Particle (Nanocomposite)
Taylor Vortex Flow Mechanism | Why Taylor Flow Reactors are Different
Taylor Vortex Flow, also called Taylor-Couette Flow is produced between two cylinders when the inner cylinder rotates in high speed, causing the solution between the inner cylinder and outer cylinder to form a strong stream moving in the opposite direction of the rotation. The higher the speed of the rotation in the inner cylinder, the less stable the flow of the solution in between the cylinders. Eddy current flow inside these unitary vortex cells in between the outer and inner cylinder walls allow vigorous homogeneous micro-mixing. On top of the macro mixing in the inner cylinder, the micro-mixing motion enables reactions that are much faster, consistent, and produces product particles that are smaller, denser and in uniform size and shape. Laminar is the first company to successfully apply Taylor Flow into a commercialized chemical reactor, allowing faster, reliable, and high quality chemical production globally.
Taylor Vortex Flow Chemical Reactor can be used synthesize new solution by injecting reactants in all forms – gas, liquid and solid with a buffer for a liquid to liquid reaction, gas to liquid reaction, and solid to liquid reaction. It produces higher yield and uniformity even at a non-calibrated state in comparison to a fully calibrated conventional reactors.
Patent Protected Chemical Reactor using Taylor Flow
United States
- Purification apparatus and method using continuous reactors (US 9,937,480B2)
- Apparatus for manufacturing particles and method utilizing apparatus for manufacturing particles (US 10,005,062B2)
- All in one continuous reactor and crystal separation apparatus for manufacturing positive electrode active material for lithium secondary battery (US 10,010,851B2)
- Reaction device and reaction method for mixing (US 10,201,797B2)
Europe
- Apparatus for manufacturing particles and method utilizing apparatus for manufacturing particles (EP 3012019B1)
- All in one continuous reactor and crystal separation apparatus for manufacturing positive electrode active material for lithium secondary battery (EP 2735366B1)
- Purification apparatus and method using continuous reactors (EP 2893964B1)
Japan
- All in one type continuous reactor and crystal separation apparatus for manufacturing positive electrode active material for lithium secondary battery (JP 5714708)
- Reaction device and it’s manufacturing method for mixing (JP 6257636)
- Refining device including a continuous reactor and refining method using this continuous reactor (JP 6352919)
- Manufacturing device and method for quantum dots (JP 6568265)
South Korea
- Reaction device for mixing and manufacturing method using the reaction device (10-1092337)
- Polarizing film to waste recovery of potassium iodide (10-2241620)
- Special cylinder for reactor (10-1239163)
- Gas-liquid reactor and reaction method for lithium secondary cathode materials (10-1361118)
- High-pressure reaction apparatus (10-1364691)
- Tryptophan purification devices and methods (10-1372811)
- Solid-liquid mixed reaction apparatus (10-1399057)
- An apparatus and method for manufacturing particles (10-1464345)
- An apparatus and method for manufacturing core-shell particles (10-1424610)
- Ultra-high purity purification device including a continuous reactor (10-1427324)
- Surface treatment method using Taylor Flow Reactor (10-1727939)
- Methods and devices for manufacturing non-oxidizing graphene using electrochemical pretreatment and shear flow exfoliation (10-1785374)
- Graphene metal nanoparticle complex (10-1866190)
- Manufacturing system and method using Couette-Taylor reactor for manufacturing graphene oxide (10-1573384)
- Eco-friendly graphene oxide manufacturing system using Couette-Taylor reactor (10-1573358)
Certificates
